Header and coil connections for a heat exchanger

ABSTRACT

A header and coil connection assembly is provided for a heat exchanger. The header is comprised of a first section of a generally half cylindrical structure and a second section of a generally half cylindrical structure. The second section has a plurality of openings each of which receives a heat exchanger tube. The heat exchanger tubes are connected to the second section by welding around the opening.

BACKGROUND OF INVENTION

The present invention relates to an improved header and method formaking a header for use in a heat exchanger or thermal storage device.

Indirect fluid cooling arrangements are comprised of a plurality oftubular passageways immersed in a pool of liquid within a vessel. Thepool of liquid itself is cooled, usually by the use of a cooling tower.In turn, the liquid passing through the plurality of tubular passagewaysis cooled by the indirect contact with the pool of cooled liquid.

Such a fluid cooling arrangement is similar to an ice storagearrangement. In an ice storage arrangement, a refrigerant liquid isprovided from a mechanical refrigeration unit through a plurality oftubular passageways immersed in a pool of liquid within a vessel. Therefrigerant acts to form ice about the tubular passageways from the poolof liquid, which is usually water. During supplemental cooling, therefrigerant liquid itself is circulated through the plurality of tubularpassageways after the refrigerant has been warmed by passing through aheat exchanger in an air conditioning or cooling system. Such arefrigerant is thusly sub-cooled by passing through the ice surroundedpassageways. The refrigerant in turn melts the ice surrounding thepassageways. This is the concept of ice thermal storage.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide animproved header for use in a heat exchanger or thermal storage device.

A header and tubular coil connection assembly is provided for use in aheat exchanger or ice thermal storage device. The header is comprised ofa first section of a generally half cylindrical structure, and a secondsection of a generally half cylindrical structure. Each of the first andsecond sections are formed of an elongated structure, typically formedinto a half cylindrical or nearly half cylindrical structure in abending operation. It is within the scope of the present invention toprovide a generally half cylindrical structure utilizing multiple bendsthat approach a purely half cylindrical form.

One of the first and second sections, which herein is referred to as asecond section, includes a plurality of openings passing through thecylindrical structure. Due to the generally half cylindrical nature ofthe first and second sections, one side of each of the first and secondsections can be considered a concave side, while the other side isconsidered a convex side. The second section has a plurality ofopenings, each of which receives a heat exchanger tube. The heatexchanger tube end which passes through the opening is an end of thetubular passageway that forms the indirect heat exchanger or ice thermalstorage coil. Each heat exchanger tube is connected to the openingthrough which it passes by a suitable means, which in the case ofgalvanized steel heat exchanger tubes and header sections, usually iscomprised of a welding operation. The welding usually is performedthrough the concave side of the second section, thereby allowing the endof the heat exchanger tube to be readily visible to the welder, allowinga complete and uninterrupted weld to be formed about the heat exchangertube and opening. Such a continuous weld is important to assure aleakproof seal between the heat exchanger tube and the header section.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings,

FIG. 1 is a perspective view of a heat exchanger with a first embodimentof a header section in accordance with the present invention;

FIG. 2 is a perspective view of the header section of the first ofembodiment of the header section;

FIG. 3 is a side view of the first embodiment of the header section;

FIG. 4 is a perspective view of a heat exchanger assembly utilizing asecond embodiment of the header of the present invention;

FIG. 5 is a perspective view of a second embodiment of a header sectionof the present invention;

And FIG. 6 is a side view of a second embodiment of the presentinvention.

DETAILED DESCRIPTION

Referring now to FIGS. 1-3, a heat exchanger is shown generally at 10 ascomprising structural support members 12, and a plurality of tubecircuits 14. Structural supports 12 are usually comprised of galvanizedsteel or stainless steel, while heat exchanger tubes 14 can be comprisedof galvanized steel, stainless steel, or other suitable materials suchas copper. Ends of heat exchanger tubes 18 are seen to extend throughopenings 20 in second header section 16. Header section 16 itself isusually comprised of galvanized steel, but can be comprised of stainlesssteel or other suitable materials such as copper.

Tubing ends 18 are seen to extend through openings 20 in second headersection 16. Second header 16 itself is seen to be comprised of anelongated, generally half cylindrical shaped structure. Second headersection 16 includes top edge 22 and bottom edge 24, which extend thelength of second header section 16. Further, second header section 16 isseen to have a concave side 26 and a convex side 28. Further, as shownin FIG. 1, first header section 29 is seen to be assembled againstsecond header section 16. First header section 29 is similar to secondheader section 16, except that it usually does not have openings toreceive heat exchanger tubes therein. In all other respects, firstheader section 29 is similar in shape and material to second headersection 16.

In assembling heat exchanger 10, heat exchanger tubes 14 are spaced andplaced within structural supports 12. The ends 18 of heat exchangertubes 14 are then placed through openings in second header section 16. Acontinuous weld is them formed around the section of tubing end 18 thatdirectly passes through and is adjacent opening 20. In this manner, byforming the welding of concave side 26 of second header section 16, acontinuous weldment is formed about tubing end 18 to ensure a completeand watertight weld. From an access point of view, it is seen to bedifficult to perform welding about the tubing end 18 at convex side 28of second header section 16, but it is possible to perform welding atcertain of tubing end of convex side 28. However, it is seen to bepreferable to perform welding from an access point of view and acontinuity point of view from concave side 26 of second header section16.

In the last step of assembling heat exchanger 10, first header section29 is placed such that its top and bottom edges contact, respectively,top edge 22 and bottom edge 24 of second header edge 16. Thenappropriate welding is performed along the junction of such edges againto produce a watertight seal between first header section 29 and secondheader section 16.

Referring now to FIGS. 4-6, a heat exchanger is shown generally at 30 ascomprising structural support members 32, and a plurality of tubecircuits 34. Structural supports 32 are usually comprised of galvanizedsteel or stainless steel, while heat exchanger tubes 34 can be comprisedof galvanized steel, stainless steel, or other suitable materials suchas copper. Ends of heat exchanger tubes 38 are seen to extend throughopenings 40 in first heat and second header section 36. Header section36 itself is usually comprised of galvanized steel, but can be comprisedof stainless steel or other suitable materials such as copper.

Tubing ends 38 are seen to extend through openings 40 in second headersection 36. Second header section 36 itself is seen to be comprised ofan elongated, generally half cylindrical shaped structure. Second headersection 36 includes top edge 42 and bottom edge 44, which extend thelength of second header section 36. Further, second header section 36 isseen to have a concave side 46 and a convex side 48. Further, as shownin FIG. 4, first header section 49 is seen to be assembled againstsecond header section 36. First header section 49 is similar to secondheader section 36, except that it usually does not have openings toreceive heat exchanger tubes therein. In all other respects, firstheader section 49 is similar in shape and material to second headersection 36.

In assembling heat exchanger 30, heat exchanger tubes 34 are spaced andplaced within structural supports 32. The ends 38 of heat exchangertubes 34 are then placed through openings 40 in second header section36. A continuous weld is them formed around the section of tubing end 38that directly passes through and is adjacent opening 40. In this manner,by forming the welding of concave side 46 of second header section 36, acontinuous weldment is formed about tubing end 38 to ensure a completeand watertight weld. From an access point of view, it is seen to bedifficult to perform welding about the tubing end 38 at convex side 48of second header section 36, but it is possible to perform welding atcertain of tubing end of convex side 48. However, it is seen to bepreferable to perform welding from an access point of view and acontinuity point of view from concave side 46 of second header section36.

In the last step of assembling heat exchanger 30, first header section49 is placed such that its top and bottom edge contact, respectively,top edge 42 and bottom edge 44 of second header edge 36. Thenappropriate welding is performed along the junction of such edges againto produce a watertight seal between first header section 49 and secondheader section 36.

1. A header for use in a heat exchanger, the header comprising agenerally cylindrical tube structure comprised of two half sections, afirst section comprised of a half generally cylindrical structure,having a first end, a second end, a top edge and a bottom edge, the topedge and the bottom edge running the length of the first section, asecond section comprised of a half generally cylindrical structurehaving a first end, a second end, a top edge and a bottom edge, the topedge and the bottom edge running the length of the second section, thesecond section having a plurality of openings between the top edge andthe bottom edge, such openings extending through the half generallycylindrical structure, the first section being joined to the secondsection along the respective top edges and bottom edges to form aheader.
 2. The header of claim 1 wherein the first section is joined tothe second section by welding along the joined top edges and bottomedges.
 3. The header of claim 1 wherein a heat exchanger tube is weldedto each of the plurality of openings in the second section.
 4. Theheader of claim 1 wherein a heat exchanger tube is welded to each of theplurality of openings in the second section and wherein the welding isperformed around each opening on a concave side of the second sectionhalf generally cylindrical structure.
 5. The header of claim 1 wherein aheat exchanger tube is welded to each of the plurality of openings inthe second section and wherein the welding is performed around eachopening on both a concave and a convex side of the second section halfgenerally cylindrical structure.
 6. A method of making a header for usein a heat exchanger comprising the steps of: providing a first sectioncomprised of a half generally cylindrical structure having a first end,a second end, a top edge and a bottom edge, the top edge and the bottomedge running the length of the first section, providing a second sectioncomprised of a half generally cylindrical structure having a first end,a second end, a top edge and a bottom edge, the top edge and the bottomedge running the length of the second section, providing a plurality ofopenings in the second section half generally cylindrical structurebetween the top edge and the bottom edge, joining at least one heatexchanger tube to one of the openings in the second section halfgenerally cylindrical structure, and joining the first section to thesecond section along the respective top and bottom edges to form aheader.
 7. The method of claim 6 wherein the heat exchanger tube isjoined to the second section half generally cylindrical structure bywelding around the opening in the second section.
 8. The method of claim7 wherein the second section has a concave side and the welding isperformed around the opening receiving the heat exchanger tube on theconcave side.
 9. The method of claim 7 wherein the second section has aconcave side and a convex side and the welding is performed around theopening receiving the heat exchanger tube on the concave side and on theconvex side.
 10. A method of making a header for use in a heat exchangercomprising the steps of: providing a first section comprised of anelongated, generally half cylindrical structure having a first end, asecond end, a top edge and a bottom edge, the top edge and the bottomedge running the length of the first section, providing a second sectioncomprised of an elongated, generally half cylindrical structure having afirst end, a second end, a top edge and a bottom edge, the top edge andthe bottom edge running the length of the first section, providing aplurality of openings in the second section between the top edge and thebottom edge, joining at least one heat exchanger tube to one of theopenings in the second section by welding around the heat exchanger tubeat the opening, and joining the first section to the second section bywelding along the respective top and bottom edges to form a header. 11.The method of claim 10 wherein the second section has a concave side andthe welding is performed at the opening receiving the heat exchangertube on the concave side of the second section.